CN1159150C - Moldable composite article and method of manufacture - Google Patents
Moldable composite article and method of manufactureDownload PDFInfo
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- CN1159150C CN1159150CCNB008059616ACN00805961ACN1159150CCN 1159150 CCN1159150 CCN 1159150CCN B008059616 ACNB008059616 ACN B008059616ACN 00805961 ACN00805961 ACN 00805961ACN 1159150 CCN1159150 CCN 1159150C
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/22—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed
- B32B5/24—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer
- B32B5/26—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by the presence of two or more layers which are next to each other and are fibrous, filamentary, formed of particles or foamed one layer being a fibrous or filamentary layer another layer next to it also being fibrous or filamentary
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B5/00—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts
- B32B5/02—Layered products characterised by the non- homogeneity or physical structure, i.e. comprising a fibrous, filamentary, particulate or foam layer; Layered products characterised by having a layer differing constitutionally or physically in different parts characterised by structural features of a fibrous or filamentary layer
- B32B5/022—Non-woven fabric
- B—PERFORMING OPERATIONS; TRANSPORTING
- B60—VEHICLES IN GENERAL
- B60R—VEHICLES, VEHICLE FITTINGS, OR VEHICLE PARTS, NOT OTHERWISE PROVIDED FOR
- B60R13/00—Elements for body-finishing, identifying, or decorating; Arrangements or adaptations for advertising purposes
- B60R13/02—Internal Trim mouldings ; Internal Ledges; Wall liners for passenger compartments; Roof liners
- B60R13/0212—Roof or head liners
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2262/00—Composition or structural features of fibres which form a fibrous or filamentary layer or are present as additives
- B32B2262/02—Synthetic macromolecular fibres
- B32B2262/0276—Polyester fibres
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2307/00—Properties of the layers or laminate
- B32B2307/70—Other properties
- B32B2307/738—Thermoformability
- B—PERFORMING OPERATIONS; TRANSPORTING
- B32—LAYERED PRODUCTS
- B32B—LAYERED PRODUCTS, i.e. PRODUCTS BUILT-UP OF STRATA OF FLAT OR NON-FLAT, e.g. CELLULAR OR HONEYCOMB, FORM
- B32B2605/00—Vehicles
- B32B2605/003—Interior finishings
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- Engineering & Computer Science (AREA)
- Mechanical Engineering (AREA)
- Textile Engineering (AREA)
- Laminated Bodies (AREA)
- Casting Or Compression Moulding Of Plastics Or The Like (AREA)
- Vehicle Interior And Exterior Ornaments, Soundproofing, And Insulation (AREA)
- Manufacture Of Macromolecular Shaped Articles (AREA)
- Nonwoven Fabrics (AREA)
Abstract
Translated fromChineseDescription
Translated fromChinese相关申请的交叉引用Cross References to Related Applications
本申请是1997年4月23日递交的美国专利申请号08/839,016的部分继续申请，其的整个内容在此引入作为参考。This application is a continuation-in-part of US Patent Application Serial No. 08/839,016, filed April 23, 1997, the entire contents of which are hereby incorporated by reference.
发明背景Background of the invention
本发明总体上说涉及一种复合制品，且更具体地说涉及一种可模压的无纺纤维复合制品。This invention relates generally to composite articles, and more particularly to a moldable nonwoven fibrous composite article.
在制备具有含有足够强度和刚度以作为汽车车身内衬的聚合物材料的制品过程中，公知的是，制取具有不同性能的可热成型材料的片材，将它们处理成层状，且然后在加热和加压下将它们在模具中压制在一起。至少使用一层赋予强度和刚度和另一层产生足以用于模压的松散材料。美国专利5,298,319公开了从外层为基本上由聚丙烯人造纤维组成的无纺布和中间层为挤出聚丙烯的纤维状复合材料制得汽车车身内衬。此种现有技术纤维复合材料是与中间层聚丙烯层的挤出同时进行组合的。两个无纺布外层的内表面通过在挤出工艺中产生的热粘合至挤出的聚丙烯表面且在该工艺中熔融的相邻表面随后变成熔化状态。使用含有同一聚合物(即聚丙烯)的三层，有助于所得制品的最终循环使用。In the process of making articles of polymeric material of sufficient strength and stiffness to serve as an automotive body lining, it is known to take sheets of thermoformable material with different properties, process them into layers, and then They are pressed together in a mold under heat and pressure. At least one layer is used to impart strength and stiffness and another layer to create a bulk material sufficient for molding. US Patent No. 5,298,319 discloses an automotive body liner made from a fibrous composite having an outer layer of nonwoven fabric consisting essentially of polypropylene rayon and a middle layer of extruded polypropylene. This prior art fiber composite is combined simultaneously with the extrusion of the interlayer polypropylene layer. The inner surfaces of the two nonwoven outer layers are bonded to the extruded polypropylene surface by the heat generated in the extrusion process and the adjacent surfaces melted in the process then become molten. The use of three layers comprising the same polymer, ie polypropylene, facilitates the ultimate recycling of the resulting article.
在这个现有技术的方法中存在几个固有的缺点。因为赋予模压所必须的松散材料的中间层是被挤出的，由此模压的制品将必须是具有均匀的厚度。另一个短处是，纤维复合材料必须与中间层的挤出同时组合。There are several inherent disadvantages in this prior art approach. Since the intermediate layer which imparts the bulk material necessary for molding is extruded, the article molded thereby will have to be of uniform thickness. Another disadvantage is that the fiber composite has to be assembled simultaneously with the extrusion of the intermediate layer.
发明综述Summary of invention
因此，本发明的一个目的是提供一种改进的可模压的纤维复合材料，其可用于制备不同厚度和密度的模压制品。It is therefore an object of the present invention to provide an improved moldable fiber composite material which can be used to prepare molded articles of different thicknesses and densities.
本发明的另一个目的是提供一种由可依次拼合的层组成的改进的可模压复合材料。Another object of the present invention is to provide an improved moldable composite material consisting of layers which can be joined together in succession.
本发明的又一个目的是提供一种由可容易地循环使用的相容材料制成的改进的可模压的纤维复合材料。It is a further object of the present invention to provide an improved moldable fiber composite material made of compatible materials which can be easily recycled.
本发明的再一个目的是提供一种能够用于模压具有高厚度重量比的制品的无纺纤维复合材料。Yet another object of the present invention is to provide a nonwoven fibrous composite material that can be used for molding articles having a high thickness to weight ratio.
本发明的还一个目的是提供一种改进的纤维复合材料，当在加热和加压下模压时，其容易变成模具的形状而不会断裂或撕裂。It is still another object of the present invention to provide an improved fiber composite material which, when molded under heat and pressure, readily takes the shape of the mold without breaking or tearing.
本发明的进一个目的是提供一种能够用于热成形制品而不需要注射树脂的改进的可模压的纤维复合材料。It is a further object of the present invention to provide an improved moldable fiber composite which can be used in thermoformed articles without the need for resin injection.
为实现前述和其它目的以及克服上述的现有技术的缺点，从具体和广义地讲本发明提供了一种可模压的无纺纤维复合材料及其制备方法。根据本发明的无纺纤维复合材料具有至少两个功能层，这两层均是由相同的可热成形的无纺聚合物化学物质或材料制成。合适的聚合物材料包括聚丙烯、聚氯乙烯、聚醋酸乙烯酯、聚酰胺、聚乙烯醇、聚乙烯、聚氨酯和聚酯。在一个优选的实施方案中，这两层是由聚酯制成。这些复合材料通常可用于但不限于制备汽车车顶内衬、车身内衬、客舱制品、行李、家具、运动制品和过滤制品。To the accomplishment of the foregoing and other objects and to overcome the above-mentioned disadvantages of the prior art, the present invention provides, in particular and broadly, a moldable nonwoven fibrous composite material and a method of making the same. The nonwoven fibrous composite material according to the present invention has at least two functional layers, both of which are made of the same thermoformable nonwoven polymer chemistry or material. Suitable polymeric materials include polypropylene, polyvinyl chloride, polyvinyl acetate, polyamide, polyvinyl alcohol, polyethylene, polyurethane and polyester. In a preferred embodiment, the two layers are made of polyester. These composites are generally useful, but not limited to, in the preparation of automotive headliners, body liners, passenger cabin articles, luggage, furniture, sporting articles, and filtration articles.
所选择的聚合物化学物质是制成具有不同和/或其它物理性能的两种不同布。至少一种布是可成形的布，其在加热和/或加压下通过最终的模压成形，具有较高程度的强度和硬度。另一种布是一种可变化的压缩布(也称之为厚度可变的布)，当在加热和/或加压下模压时，其能够具有可变的厚度和密度。在某些要求最终制品具有均匀厚度和密度的用途中，也可使用该可变的压缩布。此种可变的压缩布是美国专利号5,532,050的主题，其在此引入作为参考。在另一个实施方案中，可将构成表面布层的另一层施加至用于提高由所述复合材料的制品的外观的之一层的外表面上。功能层和表面布层可拼合成能够用作制备可成形的成品的复合材料。这里所用的术语“复合材料”包括任何堆积的连续层，无论在这些层之间的粘合是否通过化学和/或物理方式提高。复合材料相邻层的粘合可通过诸如喷涂粉粘合、使用液体分散体/溶液、压合、火焰层合、在功能层之间使用中间粘合布、和机械针刺之类的工艺而被提高，所有这些均是本领域熟练人员熟知的。The polymer chemistry is selected to make two different cloths with different and/or other physical properties. At least one of the cloths is a formable cloth which is formed by final molding under heat and/or pressure to have a high degree of strength and stiffness. Another type of cloth is a variable compression cloth (also known as a variable thickness cloth) which is capable of variable thickness and density when molded under heat and/or pressure. The variable compression cloth can also be used in certain applications where uniform thickness and density of the final article is required. Such a variable compression cloth is the subject of US Patent No. 5,532,050, which is hereby incorporated by reference. In another embodiment, another layer constituting the surface cloth layer may be applied to the outer surface of one of the layers for enhancing the appearance of the article made of said composite material. The functional layer and the surface cloth layer can be combined into a composite material that can be used to make a shapeable finished product. As used herein, the term "composite" includes any build-up of successive layers, whether or not the adhesion between the layers is enhanced by chemical and/or physical means. Adjacent layers of composites can be bonded by processes such as spray powder bonding, use of liquid dispersions/solutions, press bonding, flame lamination, use of intermediate bonding cloths between functional layers, and mechanical needling are improved, all of which are well known to those skilled in the art.
在这个概念中，还包括的是另一个实施方案，其中具有预定熔融温度范围的所选纤维的共混物是包含在影响复合材料各层之间的粘合和最终模压制品的硬度的一层或两层中。粘合发生的这个机理是可称之为“热塑性粘合”且是更充分地描述在美国专利5,456,976，栏3，第36-50行，其参考内容在此引入作为参考。然后将复合材料的片材放置到模具中，加热和/或加压成形以得到模腔的形状，并由此形成最终的制品形状。Also included in this concept is another embodiment wherein a blend of selected fibers having a predetermined melting temperature range is included in a layer that affects the bond between the layers of the composite material and the stiffness of the final molded article or two layers. The mechanism by which bonding occurs is what may be referred to as "thermoplastic bonding" and is more fully described in US Pat. No. 5,456,976,
附图的简要说明Brief description of the drawings
为了更充分地理解本发明的本质和目的，应当参照实施本发明的优选模式的详细描述，同时参照附图，其中：For a fuller understanding of the nature and objects of the invention, reference should be made to the detailed description of the preferred modes for carrying out the invention, together with the accompanying drawings, in which:
图1是本发明的一个实施方案的可模压纤维复合材料的投影图，显示了它的层状配置。Figure 1 is a perspective view of a moldable fiber composite material according to one embodiment of the present invention, showing its layered configuration.
图2是制备本发明的另一个实施方案的的模压制品的系统的示意表示。Figure 2 is a schematic representation of a system for making molded articles according to another embodiment of the present invention.
本发明的详细描述Detailed description of the invention
现将参照具体的实施方案和附图详细地描述本发明。The present invention will now be described in detail with reference to specific embodiments and drawings.
根据本发明，制品是分别由可变压缩的各个卷材或片材和可成形布层模压制得。如图2中所示，可成形布(25和26)是从导辊(分别为29和32)悬垂下来，可变的压缩布(28)是从导辊(31)悬垂下来，且选择性地，表面布层来自导辊(30)。这些布层是从它们各自的导辊送入至具有上部(33)和下部(34)的模具装置中，如图2所示。According to the present invention, articles are molded from variable compressible individual rolls or sheets and formable cloth layers, respectively. As shown in Figure 2, the formable cloth (25 and 26) is suspended from guide rolls (29 and 32, respectively), the variable compression cloth (28) is suspended from guide roll (31), and optionally Typically, the surface cloth layer comes from a guide roll (30). The layers are fed from their respective guide rolls into a mold assembly having an upper (33) and a lower (34) part, as shown in Figure 2 .
汽车车顶是由将可变压缩布和可成形布(它们含有粘结剂纤维)的各个层通过一个压制膜(其模腔的形状就是车顶内衬的形状)，因为复合材料的卷材是未卷取的。为了实施模压，复合材料是经受预定时间长度的高温和然后在模具中冷却。在各个层中的粘合剂纤维在热和/或压力下软化和/或熔融以及相互混合，且通过脱模，粘结剂纤维将冷却和硬化并将各层粘合在一起。Automotive roofs are made by passing individual layers of variable compressibility cloth and formable cloth (which contain binder fibers) through a pressed film (whose mold cavity is shaped like the headliner), because the composite roll is uncoiled. To carry out compression molding, the composite material is subjected to high temperature for a predetermined length of time and then cooled in the mold. The binder fibers in the individual layers soften and/or melt and mix with each other under heat and/or pressure, and upon demolding, the binder fibers will cool and harden and bond the layers together.
根据另一个实施方案，可成形和可变压缩布层以及选择性地表面布层在制成制品之前，是形成一个复合材料。According to another embodiment, the formable and variably compressible cloth layers and optionally the surface cloth layers are formed into a composite material prior to forming the article.
参照图1，其显示了各个层，其包括本发明的复合制品。为了容易说明，各个层的厚度没有按照刻度画出。Referring to Figure 1, there is shown the various layers comprising the composite article of the present invention. For ease of illustration, the thicknesses of the individual layers are not drawn to scale.
在图1中，包含可变压缩布的复合制品(1)是在夹在具有上表面(6)和下表面(7)的可成形布层(5)，和具有上表面(9)和下表面(10)的可成形布层(8)之间，上粘合层(14)和下粘合层(11)是分别嵌入在可变压缩布层(2)和可成形布层(5)和(8)之间，以致于可变压缩层(2)的上表面紧靠粘合层(14)的下表面，以及粘合层(14)的上表面(15)紧邻可成形布层(5)的下表面(7)，以及粘合层(11)的上表面(12)紧邻可变压缩层(2)的下表面(4)，且粘合层(11)的下表面(13)紧邻可成形布层(8)的上表面(9)，由此提高了可成形布层(5)和可变压缩层(2)之间的粘合。In Figure 1, a composite article (1) comprising a variable compressible cloth is sandwiched between a formable cloth layer (5) having an upper surface (6) and a lower surface (7), and having an upper surface (9) and a lower Between the formable cloth layers (8) on the surface (10), the upper adhesive layer (14) and the lower adhesive layer (11) are respectively embedded in the variable compression cloth layer (2) and the formable cloth layer (5) and (8), so that the upper surface of the variable compression layer (2) is close to the lower surface of the adhesive layer (14), and the upper surface (15) of the adhesive layer (14) is adjacent to the formable cloth layer ( 5), and the upper surface (12) of the adhesive layer (11) is next to the lower surface (4) of the variable compression layer (2), and the lower surface (13) of the adhesive layer (11) In close proximity to the upper surface (9) of the formable cloth layer (8), thereby improving the adhesion between the formable cloth layer (5) and the variable compressibility layer (2).
前述的实施方案可通过利用粘合层(20)将表面布层(17)的下表面(19)施加至可成形布层(5)的上表面(6)而改性，以致于表面布层(17)的下表面(19)紧邻粘合层(20)的上表面(21)，且粘合层(20)的下表面(22)紧邻可成形布层(5)的上表面(6)，由此提高了复合材料及其模压制品的外表面的外观。汽车内衬或车身内衬可然后通过将该复合材料穿过压模装置而成形，并使该复合材料经受高温和/或高压，其时间是足以使该复合材料形成所述模腔的形状。The foregoing embodiments may be modified by applying the lower surface (19) of the surface cloth layer (17) to the upper surface (6) of the formable cloth layer (5) by means of an adhesive layer (20) such that the surface cloth layer The lower surface (19) of (17) is adjacent to the upper surface (21) of the adhesive layer (20), and the lower surface (22) of the adhesive layer (20) is adjacent to the upper surface (6) of the formable cloth layer (5) , thereby improving the appearance of the outer surface of the composite material and its molded products. An automotive or body liner can then be shaped by passing the composite material through a compression molding apparatus and subjecting the composite material to high temperature and/or pressure for a time sufficient to form the composite material into the shape of the mold cavity.
为了用于本发明中，已发现可成形或硬化的布的基重应当是4-18盎司/平方码。优选的范围是6-12盎司/平方码。这些范围使得得到制备时手感、模压成品的受控硬度性能以及制备成品的经济性的最佳组合。For use in the present invention, it has been found that the formable or stiffened cloth should have a basis weight of 4-18 oz/yd2. A preferred range is 6-12 oz/yd2. These ranges allow for the optimum combination of hand upon manufacture, controlled hardness properties of the molded product, and economics of manufacture of the finished product.
在本发明的另一个实施方案中，聚酯可变压缩布的片材是夹杂在为针刺毛毡形状的可成形聚酯的两个片材之间，由此制得以复合材料制品。所述针刺毛毡是由纽约尤蒂卡的诺尔顿无纺布有限公司制造。相邻片材之间的粘合性是通过机械针刺而提高。然后将复合材料卷成储存卷材。可将一层装饰布，诸如HOF AHMV8印刷的缝编聚酯或Foss针刺聚酯，施加至一层可成形聚酯布的外表面上。In another embodiment of the present invention, a sheet of polyester variable compression cloth is sandwiched between two sheets of formable polyester in the shape of a needle felt, thereby making a composite article. The needle felt is manufactured by Knowlton Nonwovens, Utica, New York. Adhesion between adjacent sheets is enhanced by mechanical needling. The composite material is then rolled into storage rolls. A layer of trim fabric, such as HOF AHMV8 printed stitchbonded polyester or Foss needle punched polyester, can be applied to the outer surface of a layer of formable polyester fabric.
一种制品，例如汽车车身内衬或车顶内衬，是在加热和/或加压下在模具中形成。然后将模压制品冷却至环境温度。上述的US 5,298,319教示了用于制备本发明所称类型的制品的基本模压方法和设备，且在此引为参考。An article, such as an automotive bodyliner or headliner, is formed in a mold under heat and/or pressure. The molded article is then cooled to ambient temperature. The aforementioned US 5,298,319 teaches a basic molding method and apparatus for making articles of the type claimed in the present invention and is hereby incorporated by reference.
应理解的是，提高粘合性的不同方法可在具有相同复合材料的不同布层之间应用。例如，表面布层和可成形布层之间的高粘合可通过粘合层之间的嵌入而实施，同时可成形布层和可变厚度布层之间的高粘合可通过针刺法实施。It should be understood that different methods of improving adhesion may be applied between different cloth layers of the same composite material. For example, high adhesion between surface cloth layer and formable cloth layer can be achieved by embedding between adhesive layers, while high adhesion between formable cloth layer and variable thickness cloth layer can be achieved by needle punching implement.
另外，适合于模压的复合材料可从一层可成形布和一层可变压缩布制成。表面布层可施加至可成形布层或可变压缩布层之一的外表面上。功能布层之间的粘合可通过诸如针刺之类的机械装置手段和/或通过诸如喷涂粉粘合、使用液体分散体和/或溶液、火焰层合、和/或粘合层的嵌入以及它们的组合等粘合方法而被提高。Alternatively, composite materials suitable for molding can be made from one layer of formable cloth and one layer of variable compressibility cloth. The surface cloth layer may be applied to the outer surface of one of the formable cloth layer or the variable compressible cloth layer. Bonding between functional fabric layers can be by mechanical means such as needle punching and/or by means such as spray powder bonding, use of liquid dispersions and/or solutions, flame lamination, and/or embedding of adhesive layers And their combination and other bonding methods are improved.
下列实施例显示了本发明的各种结构实施方案和如何通过改变某些工艺参数而控制本发明的结构的物理性能。在下列实施例中，第一和第二硬挺剂层是通过针刺方法制得：首先将所选的纤维在标准纺织混合设备上掺混，随后将所述纤维梳理成无纺布，其然后将其交叠铺网以制得高柔软的多层毛毡，随后将该毛毡层用约1000针的穿刺进行针刺。The following examples show various structural embodiments of the invention and how the physical properties of the structures of the invention can be controlled by varying certain process parameters. In the following examples, the first and second stiffener layers were produced by needling by first blending the selected fibers on standard textile blending equipment, followed by carding the fibers into a nonwoven, which was then This was crosslaid to produce a highly soft multi-ply felt which was subsequently needle punched with about 1000 needle punches.
实施例Example
其中一层可变压缩布是夹在两层或两片可成形(硬挺剂)布之间的一种可模压的复合材料结构是通过通过下列工艺制得。A moldable composite structure in which a layer of variable compressibility cloth is sandwiched between two layers or sheets of formable (stiffener) cloth is produced by the following process.
三种材料层是如下：The three material layers are as follows:
第一硬挺剂层 50％Fiber Inovation Technologies 3.5旦×5.08厘米(2英寸)结晶聚酯双组分粘结剂纤维50％Kosa 15旦×7.62厘米(3英寸)295型First stiffener layer 50% Fiber Innovation Technologies 3.5 denier x 5.08 cm (2 inches) crystalline polyester bicomponent binder fiber 50
聚酯polyester
基重-6盎司/平方码Basis Weight - 6 oz/sq yd
针刺法织造(硬挺剂布)Needle punching (stiffener cloth)
第二硬挺剂层 与上述相同的纤维、混纺纱、和织造Second stiffener layer Same fiber, yarn blend, and weave as above
基重-9盎司/平方码Basis Weight - 9 oz/sq yd
可变压缩层 50％Fiber Innovation Technologies 3.5旦×5.08Variable compression layer 50% Fiber Innovation Technologies 3.5 denier × 5.08
厘米(2英寸)结晶聚酯双组分粘结剂纤维cm (2 in.) crystalline polyester bi-component binder fiber
25％6.7分特聚酯 25% 6.7 dtex polyester
25％17.0分特聚酯 25% 17.0 dtex polyester
基重-20盎司/平方码Basis Weight - 20 oz/sq yd
厚度-20毫米 Thickness - 20mm
纵向搭接织造(可变压缩布) Longitudinal lap weaving (variable compression cloth)
在这些材料的每个之间没有粘合层。纵向搭接产物可变压缩布是在Strudo machine上制得，该机器的厂商是：There is no adhesive layer between each of these materials. The variable compression fabric of the longitudinally lapped product is made on a Strudo machine, and the manufacturer of the machine is:
I.N.T.，s.r.oI.N.T., s.r.o.
460 05 liberec，Karla Capka 302/22460 05 liberec, Karla Capka 302/22
捷克共和国Czech Republic
为了制备所述可变压缩层，将所述三个聚酯纤维(包括一粘合剂纤维)在标准的纺织纤维掺混设备上掺混并梳理成无纺布。将梳理的布送入纵向搭接Strudo机以使其折叠或打褶，从而得到给定厚度的纵向折叠的产品。将该厚产品通过一烘箱以将该产品加热至至少约150℃，其软化或熔融粘结剂纤维以使得它们热粘合至共混物中的其它纤维上，由此制得一个柔软、厚的三维产品。To prepare the variable compression layer, the three polyester fibers (including a binder fiber) were blended and carded into a nonwoven on standard textile fiber blending equipment. The carded cloth is fed into a longitudinally lapping Strudo machine to fold or pleat it, resulting in a longitudinally folded product of a given thickness. Pass the thick product through an oven to heat the product to at least about 150° C., which softens or melts the binder fibers so that they thermally bond to other fibers in the blend, thereby producing a soft, thick 3D products.
为了制得上述的模压制品，所述工艺包括，将所述布层压成一复合材料，将该复合材料预热至约400°F达约8分钟，将该复合材料放入至模具中，关闭模具成16毫米的缝隙达约4分钟，并开模以取出模压制品、对于温热的模具试样而言，该模具(温热工具)是被预热至约300°F。To make the molded article described above, the process includes laminating the cloth into a composite, preheating the composite to about 400°F for about 8 minutes, placing the composite in a mold, closing The mold was gapped at 16 mm for about 4 minutes and opened to remove the molded article. For warm mold samples, the mold (warm tool) was preheated to about 300°F.
复合三层试样是：可变压缩层是夹在沿纵向和横向方向制成的第一和第二硬挺剂层之间。具有相同组成的其它试样是使用未经加热的模具(冷工具)在室温下沿纵向和横向方向制成。根据上述方法制成的四种试样是使用ASTM设计D790-92、测试方法I-A三点载荷系统(中心是在一个简单支撑的横梁上)，按照用于未增强的和增强的塑料以及电绝缘材料的挠曲性能的标准测试方法进行测试。The composite three-layer specimen is: the variable compressibility layer is sandwiched between the first and second stiffener layers made in the longitudinal and transverse directions. Other samples with the same composition were produced in longitudinal and transverse directions at room temperature using unheated molds (cold tools). The four specimens made according to the above method were tested using ASTM Design D790-92, Test Method I-A Three-Point Loading System (centered on a simply supported beam), as used for unreinforced and reinforced plastics and electrical insulation Standard test method for flexural properties of materials.
测试结果是列于下表1中。The test results are listed in Table 1 below.
表1 挠曲测试结果
*SSL＝第二硬挺剂层* SSL = second stiffener layer
VCL＝可变压缩层VCL = Variable Compression Layer
FSL＝第一硬挺剂层FSL = first stiffener layer
对本发明的模压复合材料提供合适硬挺度的操作范围是对补偿屈服载荷为约13-26牛顿。本发明的1英寸屈服载荷是约90-140％，且斜率硬度是在约2.5-7.0牛顿/毫米的范围。The operating range to provide suitable stiffness for the molded composites of the present invention is about 13-26 Newtons to compensate yield load. The 1 inch yield load of the present invention is about 90-140%, and the slope hardness is in the range of about 2.5-7.0 N/mm.
本发明的产品在一个优选实施方案中，要求高的硬挺度以适合用于汽车车顶内衬，术语“高的硬挺度”是通过在表1中介绍和上面讨论的挠曲结果和定义的。模压车顶内衬要求高的硬挺度以为了在它的跨度(在微型蓬车中其可以是高达8英尺)内支撑它自己的重量，和室内灯和太阳镜的额外重量，而当按用于车顶内衬的标准环境耐受测试中所评估暴露高达3天时，在从-40℃至185°F的宽温度范围内不会弯曲和断裂。产品必须不被挠曲或弯曲至破坏点，在该破坏点车顶内衬将破裂，使它不能承受所加车顶内衬组分的重量。而且，车顶内衬中的破坏断裂将通过该车顶内衬中的装饰性布层显示出来，使得外观不够美观，不宜安装在汽车中。当应力超过它的极限时，本发明的产品将弯曲且然后破坏断裂，因为上述原因使其不适合用作汽车车顶内衬。“低模量”产品不会破坏断裂，且没有表现出承受在使用时所加元件重量所需的硬挺度，特别是在上述的环境耐受测试中。因此，低模量产品本来是不适合用于汽车车顶内衬。The product of the present invention, in a preferred embodiment, requires high stiffness to be suitable for use in automotive headliners, the term "high stiffness" is defined by the flexural results presented in Table 1 and discussed above . The molded headliner requires a high degree of stiffness in order to support its own weight within its span (which can be as high as 8 feet in a minivan), and the additional weight of interior lights and sunglasses, and when pressed for The headliner will not bend and break over a wide temperature range from -40°C to 185°F when exposed to up to 3 days as assessed in the Standard Environmental Resistance Test. The product must not be flexed or bent to the point of failure at which the headliner would rupture making it unable to bear the weight of the added headliner components. Also, a destructive fracture in the headliner will show through the decorative fabric layer in the headliner, making it less aesthetically pleasing for installation in a car. When the stress exceeds its limit, the product of the present invention will bend and then fail to fracture, making it unsuitable for use as an automotive headliner for the above reasons. "Low modulus" products do not fail to break and do not exhibit the stiffness necessary to withstand the weight of the added components in use, particularly in the environmental resistance test described above. Therefore, low modulus products are inherently unsuitable for automotive headliners.
虽然在此描述了本发明的各个实施方案，但这些仅仅是用于解释和说明本发明的目的，且不应理解为限制本发明的范围。对本领域技术人员将是十分明显的本发明的各种改进是处于本发明的范围之内，且是包括在所附的权利要求书中。While various embodiments of the invention have been described herein, these have been presented for purposes of illustration and description only, and should not be taken as limiting the scope of the invention. Various modifications of the invention which will be apparent to those skilled in the art are within the scope of the invention and are encompassed in the appended claims.
虽然参照如附图中所示的优选模式，已具体地显示和描述本发明，但本领域技术人员应理解的是，在不偏离权利要求书所定义的本发明的精神实质和范围之内的情况下，可详细地实施各种改变。Although the present invention has been specifically shown and described with reference to the preferred modes as shown in the accompanying drawings, those skilled in the art should understand that, without departing from the spirit and scope of the present invention defined by the claims case, various changes can be implemented in detail.
Claims (20)
Translated fromChineseApplications Claiming Priority (2)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| US09/286,916US6008149A (en) | 1997-04-23 | 1999-04-06 | Moldable composite article and method of manufacture |
| US09/286,916 | 1999-04-06 |
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| CN1346308A CN1346308A (en) | 2002-04-24 |
| CN1159150Ctrue CN1159150C (en) | 2004-07-28 |
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| ITSV20020063A1 (en)* | 2002-12-30 | 2004-06-30 | Compass Sa | SHAPED PANEL IN THERMOPLASTIC MATERIAL, INTERMEDIATE SHEET FOR THE MANUFACTURE OF THE SAID PANEL AND PROCEDURE FOR THE MANUFACTURE OF THE SAID PANEL AND OF THE INTERMEDIATE SHEET |
| HUE027241T2 (en)* | 2011-10-31 | 2016-11-28 | Ind S P A | Article made of a multilayer composite material and preparation method thereof |
| RU2619711C2 (en)* | 2012-06-26 | 2017-05-17 | Сан Шян Текнолоджи Ко., Лтд. | Manufacture method of nonwoven composite laminated product with different hardness degree |
| DE102019100919A1 (en)* | 2019-01-15 | 2020-07-16 | Adler Pelzer Holding Gmbh | Motor vehicle floor covering, luggage compartment covering or loading floor covering with textured needle-punched carpet surface (II) |
| DE202021103471U1 (en) | 2021-06-29 | 2021-07-07 | Tenowo GmbH | Composite material based on non-woven fabrics |
| EP4241979A1 (en)* | 2022-03-10 | 2023-09-13 | Carl Freudenberg KG | Sustainable nonwoven laminate for structural part applications |
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| JPS60196332A (en)* | 1984-03-17 | 1985-10-04 | Ikeda Bussan Co Ltd | Manufacture of interior ornamental material for vehicle |
| US5532050A (en)* | 1986-06-30 | 1996-07-02 | Wm. T. Burnett & Co., Inc. | Densified thermo-bonded synthetic fiber batting |
| MX170360B (en)* | 1987-08-28 | 1993-08-18 | Gates Formed Fibre Products | SEMI-RIGID LUGGAGE COVER AND METHOD FOR ITS PRODUCTION |
| JP3351475B2 (en)* | 1992-10-03 | 2002-11-25 | ユニチカ株式会社 | Laminated plate and method of manufacturing the same |
| JPH06199182A (en)* | 1993-01-06 | 1994-07-19 | Dainippon Ink & Chem Inc | Manufacturing method for car trunk side trim |
| US5591289A (en)* | 1995-06-29 | 1997-01-07 | Davidson Textron Inc. | Method of making a fibrous headliner by compression molding |
| WO1998030375A1 (en)* | 1997-01-08 | 1998-07-16 | Owens Corning | Molding media and process of making same |
| US6096669A (en)* | 1997-10-28 | 2000-08-01 | Gkn Westland Aerospace Inc. | Unidirectional fiber-random mat preform |
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